Information injection-pump assembly
ZEXEL
106671-9180
1066719180
Rating:
Cross reference number
ZEXEL
106671-9180
1066719180
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
1404 Test oil ISO4113 or {SAEJ967d}
Test oil temperature
degC
40
40
45
Nozzle and nozzle holder
105780-8140
Bosch type code
EF8511/9A
Nozzle
105780-0000
Bosch type code
DN12SD12T
Nozzle holder
105780-2080
Bosch type code
EF8511/9
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
134424-1420
Overflow valve opening pressure
kPa
162
147
177
Overflow valve opening pressure
kgf/cm2
1.65
1.5
1.8
Tester oil delivery pressure
kPa
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
Direction of rotation (viewed from drive side)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-4-2-6-
3-5
Pre-stroke
mm
4
3.94
4
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
A
Rack position
10.2
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
136
134
138
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Boost pressure
kPa
60
60
Boost pressure
mmHg
450
450
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.3+-0.5
Pump speed
r/min
260
260
260
Average injection quantity
mm3/st.
8
5
11
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
G
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
135
130
140
Fixing the lever
*
Boost pressure
kPa
60
60
Boost pressure
mmHg
450
450
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
R1(8.5)
Boost pressure
kPa
20
18.7
21.3
Boost pressure
mmHg
2.7
-7.3
12.7
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
10
Boost pressure
kPa
46.7
46.7
46.7
Boost pressure
mmHg
350
350
350
Timer adjustment
Pump speed
r/min
1000--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
950
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1150
Advance angle
deg.
2
1.5
2.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Tolerance for racks not indicated: +-0.05mm.
(2)RACK LIMIT
(3)Boost compensator stroke: BCL
(4)Damper spring setting
(5)Rack difference between N = N1 and N = N2
(6)Microswitch not operating at delivery.
(7)Set idle at point K (N = N2, R = R2) and confirm that the injection quantity does not exceed Q1 at point J (N = N4).
(8)Boost compensator cancel stroke: BSL
----------
BCL=1.5+-0.1mm N1=1150r/min N2=700r/min N3=300r/min N4=1150r/min R1=6.3mm Q1=3mm3/st BSL=2.2mm
----------
----------
BCL=1.5+-0.1mm N1=1150r/min N2=700r/min N3=300r/min N4=1150r/min R1=6.3mm Q1=3mm3/st BSL=2.2mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=(4deg)+-5deg
----------
----------
a=(4deg)+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
(2)Use the hole at R = aa
----------
aa=65mm
----------
a=22deg+-5deg b=23.5deg+-3deg
----------
aa=65mm
----------
a=22deg+-5deg b=23.5deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the pin at R = aa
----------
aa=30mm
----------
a=64deg+-5deg b=44deg+-5deg
----------
aa=30mm
----------
a=64deg+-5deg b=44deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(50deg)
----------
----------
a=(50deg)
Information:
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
New DEF sensor kits are available. The new sensor kit allows the DEF sensor to be repaired on DEF manifold assemblies.Note: If troubleshooting procedures indicate a replacement of the DEF manifold, do not replace the DEF Manifold. Repair the DEF Manifold using the DEF manifold sensor kit.Refer to Table 1 for the appropriate DEF sensor kit for the DEF manifold installed.
Table 1
DEF manifold Part Number Part Description Repair with DEF Sensor Kit
462-3219 11 inch (279mm) Manifold 593-0641
462-3610 13 inch (330mm) Manifold 593-0642
462-3232 18 inch (457mm) Manifold 593-0643
Illustration 1 g06508474New disassembly and assembly instructions are available. Refer to Disassembly and Assembly, Manifold (DEF Heater) - Disassemble and Disassembly and Assembly, Manifold (DEF Heater) - Assemble for the correct procedures.